Method and apparatus for production of a cast component

ABSTRACT

A system for producing cast components from molten metal. One form of the present invention includes a system for the precision pouring of molten metal within a casting mold. The precision pouring system is driven by a pressure differential.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a divisional of U.S. patent application Ser.No. 10/633,439 filed Aug. 1, 2003, which is a divisional of U.S. patentapplication Ser. No. 10/462,168 filed Jun. 16, 2003, which is acontinuation of U.S. patent application Ser. No. 09/444,155 filed Nov.20, 1999, which is a continuation-in-part of U.S. patent applicationSer. No. 09/322,863 filed May 28, 1999, which claims the benefit of U.S.Patent Application No. 60/109,298 filed Nov. 20, 1998, each of which areincorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates generally to a method and apparatus forthe production of a cast component. More particularly, in one embodimentof the present invention, a single cast single crystal structure isformed by the directional solidification of a superalloy within aprecision casting mold containing a starter seed. Although the inventionwas developed for casting gas turbine engine components, certainapplications may be outside of this field.

The performance of a gas turbine engine generally increases with anincrease in the operating temperature of a high temperature workingfluid flowing from a combustion chamber. One factor recognized by gasturbine engine designers as limiting the allowable temperature of theworking fluid is the capability of the engine components to not degradewhen exposed to the high temperature working fluid. The airfoils, suchas blades and vanes, within the engine are among the components exposedto significant thermal and kinetic loading during engine operation.

One cooling technique often utilized in a gas turbine engine componentis an internal network of apertures and passageways. A flow of coolingmedia is passed through the internal passageways of the component, andexhausted onto the exterior surface of the component. The passage of thecooling media through the internal passageways provides for heattransfer from the component to the cooling media.

A process and apparatus are disclosed in U.S. Pat. No. 5,295,530, whichis incorporated herein by reference, by which the production of a hightemperature thin wall cast structure is described. The '530 patentdescribes a process of pouring a molten metal into a ceramic castingmold which is carried on a water-cooled chill plate within a vacuumfurnace. The injection pressure of the molten metal can be varied overtime so that the walls of the casting mold do not substantially distortduring the process. Thereafter, the molten metal within the casting moldis directionally solidified.

Although the prior techniques can produce thin walled cast componentswith internal passageways and apertures, there remains a need for animproved method and apparatus for casting a component. The presentinvention satisfies this and other needs in a novel and unobvious way.

SUMMARY OF THE INVENTION

One form of the present invention contemplates an apparatus, comprising:a metallic seed applicable to grow at least one crystal by directionalsolidification of a molten metal, the starter seed has a portion forreceiving the molten metal thereon and at least one internal passagewayadapted for the passage of a heat transfer media.

Another form of the present invention contemplates a metallic seedcrystal for the use in solidification of a molten metal to an article.The seed crystal, comprising: a metallic member having a melt end and abase end with a melt portion and a non-melt portion therebetween, thebase end defines a first surface adapted to contact a heat sink totransfer heat from the member; and, the melt portion formed at the meltend and adapted for receiving molten metal thereagainst, the meltportion has an unmelted state with a cross sectional area less than thearea of the first surface and a melted state wherein the melt portionhas a cross sectional area substantially equal to the first surface soas not to restrict heat transfer to the base end.

Another form of the present invention contemplates an apparatus forexchanging heat with a metallic starter seed during the directionalsolidification of a molten metal. The apparatus, comprising: at leastone member for mechanically gripping the metallic starter seed andmaintaining a heat transfer path with the starter seed as the metalmaterial solidifies; and a heat transfer sink connected with the atleast one member for removing heat therefrom.

Yet another form of the present invention contemplates an apparatus,comprising: a crucible having a discharge; a vacuum furnace having thecrucible positioned therein for melting metal material within thecrucible; a metallic starter seed; a casting mold having an openingadapted to receive the starter seed and an internal cavity for receivingthe molten metal material discharged from the discharge, the starterseed is positioned within the opening and contactable by the moltenmetal material received in the internal cavity; and, a heater coupledwith the starter seed to selectively add energy to the starter seedduring a first period, and wherein the starter seed is joined to themetal poured in the cavity and heat is withdrawn through the starterseed during the directional solidification of the metal material withinthe cavity.

Yet another form of the present invention contemplates an apparatus forpouring a molten metal. The apparatus, comprising: a crucible having abottom wall member with an aperture formed therethrough; an upstandingfirst tube positioned within the crucible and having a first end locatedaround the aperture and coupled to the bottom wall member and anothersecond end that is closed, the first tube having at least one entrancefor allowing the passage of molten metal from the crucible to the firsttube; an upstanding second tube located within the first tube and havingone end coupled to the bottom wall member and in fluid communicationwith the aperture and another end defining an inlet from the tube, thesecond tube has a first cavity adapted for receiving a volume of moltenmetal therein; and a passageway extending along the second tube for thepassage of the molten metal from the at least one entrance to the inlet.

Yet another form of the present invention contemplates, a method forpouring molten metal into a casting mold within a furnace. The method,comprising: providing a crucible with a discharge aperture and a pourassembly located within the crucible, the pour assembly including anupstanding outer tube positioned around an upstanding inner tube, theinner tube is in fluid communication with the discharge aperture;melting a metal material within the crucible to a liquid state; flowingthe liquid state metal from the crucible into a cavity defined betweenthe outer tube and the inner tube; overfilling the cavity so that liquidstate metal flows into and fills the inner tube; stopping the filling ofthe inner tube; and discharging the liquid state metal from the innertube.

Yet another form of the present invention contemplates an apparatus forpouring a molten metal. The apparatus, comprising: a mechanical housingwith a bottom wall member and an interior volume adapted to hold amolten metal; and a molten metal delivery member having a first moltenmetal inlet end adapted to receive molten metal from below the surfaceof the molten metal within the interior volume and a second molten metaloutlet end with a passageway therebetween, at least a portion of thedelivery member positioned within the mechanical housing, the passagewayhas a first passageway portion and a second passageway portion and ainflection portion wherein the direction of molten metal flow changes,in a first discharge mode a first direction of molten metal flow withinthe first passageway portion is from the molten metal inlet to theinflection portion and from the inflection portion through the secondpassageway portion in a second direction to said outlet.

Yet another form of the present invention contemplates a casting mold,comprising: a free form fabricated ceramic shell, the ceramic shellhaving a thin first outer wall defining a cavity therein that is adaptedfor receiving a molten metal; a container having a second outer wallwith an inner surface, wherein the shell is positioned within thecontainer and spaced from the inner surface; and at least one supportmember substantially filling the space between the first outer wall andthe inner surface and reinforcing said shell.

Yet another form of the present invention contemplates a a method,comprising: providing a mold having an internal cavity adapted for thereceipt of molten metal therein, the cavity has a top portion, bottomportion and side portion, insulating the ceramic shell to minimize heattransfer through said side portion; placing the mold within anenvironmental control chamber; filling the cavity with molten metal toform a casting defined by the cavity; and directionally solidifying themolten metal within the mold by withdrawing energy from one end of thecasting.

Yet another form of the present invention contemplates a method,comprising: providing a casting mold having a plurality of layers of amaterial bonded together to define a cavity for receiving a molten metalmaterial therein and an exit in communication with the cavity; orientingthe casting mold at an inclination; rotating the casting mold to freeany material located within the cavity and not bonded to one of theplurality of layers of material; and passing the material located withinthe cavity out of the cavity and through the exit.

Yet another form of the present invention contemplates a method,comprising: building a integral ceramic casting mold shell by a freeform fabrication technique, the casting mold shell has an internalcavity adapted to receive a molten metal; reinforcing the ceramiccasting mold shell; positioning a metallic starter seed within theceramic casting mold shell, the metallic starter seed is positioned toreceive molten metal therein; filling the internal cavity with moltenmetal; and withdrawing heat through the metallic starter seed todirectionally solidify the molten metal within the internal cavity.

One object of the present invention is to provide a unique system forproduction of a cast component.

Related objects and advantages of the present invention will be apparentfrom the following description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustrative view of a gas turbine engine.

FIG. 2 is a perspective view of a gas turbine engine blade within theFIG. 1 gas turbine engine.

FIG. 3 is a plan view of one embodiment of an internal coolingpassageway comprising a portion of the FIG. 2 gas turbine engine blade.

FIG. 4 is a cross section of one embodiment of a cast airfoil having athin outer wall.

FIG. 5 is an illustration of one embodiment of a cast multi-wallstructure.

FIG. 6 is an illustration of one embodiment of an atmosphericair/spacecraft having a leading edge made with a process according toone aspect of the present invention.

FIG. 7 is an illustration of one embodiment of a cast valve body.

FIG. 8 is an illustration of the growth of dendrites from a starterseed.

FIG. 9 is an illustrative view of a portion of a casting mold accordingto one embodiment of the present invention.

FIG. 10 is an illustrative view of a portion of a casting mold accordingto another embodiment of the present invention.

FIG. 11 is an illustrative view of the casting mold of FIG. 10 upon thesubstantial completion of the build cycle.

FIG. 12 is a flow chart of one embodiment of a method for creating abuild file for a casting mold system.

FIG. 13 is an illustrative view of the casting mold of FIG. 10 beingfabricated by a stereolithography process.

FIG. 14 is an illustrative view of the casting mold of FIG. 10 with theboundaries defining the layers of the layered build structure amplified.

FIG. 15 is an enlarged illustrative view of a portion of the layeredbuild structure of FIG. 14.

FIG. 16 is an illustrative view of an alternate embodiment of a wallstructure comprising a portion of the FIG. 10 casting mold.

FIG. 17 is an illustrative view of an alternate embodiment of a wallstructure comprising a portion of the FIG. 10 casting mold.

FIG. 18 is an illustrative view of an alternative embodiment of a corecomprising a portion of the FIG. 10 casting mold.

FIG. 19 is an illustrative view of an alternative embodiment of a corecomprising a portion of the FIG. 10 casting mold.

FIG. 20 is an illustrative sectional view of an alternative embodimentof a casting mold of the present invention.

FIG. 21 is a perspective view of the casting mold of FIG. 20.

FIG. 22 is a sectional view taken along line 22-22 of the casting moldof FIG. 20.

FIG. 23 is an illustrative sectional view of another embodiment of acasting mold of the present invention.

FIG. 24 is a diagrammatic representation of a casting mold within afurnace for sintering the green ceramic mold.

FIG. 25 is an illustration of a free form fabricated integral castingmold according to one embodiment of the present invention which furthercomprises a top member.

FIG. 26 is a partially fragmented view of a mold container with theintegral casting mold of FIG. 25 positioned therein.

FIG. 27 is a partially fragmented view of an alternate embodiment of themold container of FIG. 26 that further comprises a heating ring.

FIG. 28 is a cross sectional view of FIG. 27 taken along line 28-28.

FIG. 29 is a cross sectional view of an alternate embodiment of the moldcontainer of FIG. 27, which further includes a heater.

FIG. 30 is an illustration of a system for removing unbonded materialfrom a casting mold.

FIG. 31. is an illustrative view of one embodiment of the system of FIG.30 for removing the unbonded material from the casting mold.

FIG. 32 is an illustrative view of one embodiment of a casting system ofthe present invention.

FIG. 33 is an illustrative sectional view of one embodiment of thecasting apparatus for casting a component of the present invention.

FIG. 34 is an illustrative plan view of the FIG. 33 casting apparatus.

FIG. 35 is an illustrative sectional view of an alternate embodiment ofthe casting apparatus for casting a component of the present invention.

FIG. 36 is an illustrative sectional view of an alternate embodiment ofthe casting apparatus for casting a component of the present invention.

FIG. 37 is an illustrative sectional view of an alternate embodiment ofthe casting apparatus for casting a component of the present invention.

FIG. 38 is an illustrative perspective view of one embodiment of theheat transfer apparatus for transferring energy with a starter seed.

FIG. 39 is an illustrative perspective view of the heat transferapparatus of FIG. 38, which further comprises an electrical means forheating the starter seed.

FIG. 40 is an illustrative sectional view of an alternate embodiment ofa heat transfer apparatus for transferring energy with a starter seedlocated within a mold container and the apparatus is in an openposition.

FIG. 41 is an illustrative sectional view of the heat transfer device ofFIG. 40 in a closed position.

FIG. 42 is an illustrative sectional view of an alternate embodiment ofa heat transfer apparatus for transferring energy with a starter seedwithin a casting mold.

FIG. 43 is an illustrative sectional view of an alternate embodiment ofthe heat transfer apparatus for transferring energy with a starter seedlocated within a casting.

FIG. 44 is an illustrative sectional view of an alternate embodiment ofa heat transfer apparatus for removing heat from a casting mold.

FIG. 45 is a perspective view of the heat transfer apparatus of FIG. 44.

FIG. 46A is an illustrative view of a portion of a casting mold having ametallic starter seed therein.

FIG. 46B is an illustrative sectional view taken along lines 46-46 ofFIG. 46A.

FIG. 47A is an illustrative perspective view of one embodiment of ametallic starter seed.

FIG. 47B is an illustrative perspective view of the metallic starterseed of FIG. 47A after a quantity of molten metal has passed thereover.

FIG. 47C is an illustrative perspective view of the metallic starterseed of FIG. 47B after an additional quantity of molten metal has passedthereover.

FIG. 48 is an illustrative view of an alternate embodiment of a starterseed of the present invention.

FIG. 49 is an illustrative view of a starter seed of the presentinvention including a passage therethrough.

FIG. 50 is an illustrative sectional view of an alternative embodimentof the molten metal delivery system located within a casting apparatus.

FIG. 51 is an illustrative sectional view of an alternate embodiment ofthe molten metal delivery system located within a casting apparatus.

FIG. 52 is an enlarged view of the molten metal delivery system of FIG.33.

FIG. 52 a is an illustrative view of an alternate embodiment of a moltenmetal delivery system.

FIG. 53A is an illustration of the molten metal delivery system of FIG.52 in a first stage.

FIG. 53B is an illustration of the molten metal delivery system of FIG.52 in a second stage.

FIG. 53C is an illustration of the molten metal delivery system of FIG.52 in a third stage.

FIG. 53D is an illustration of the molten metal delivery system of FIG.52 in a fourth stage.

FIG. 53E is an illustration of the molten metal delivery system of FIG.52 in a fifth stage.

FIG. 54 is a graphic illustration of the process of varying chargepressure with time.

FIG. 55 is an illustrative view of the gas turbine engine blade of FIG.2 within a pressure and temperature environment.

FIG. 56 is an illustrative view of a directionally solidified startercrystal with a molten metal solidifying thereon to form a directionalsolidified multi-crystal product.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

For the purposes of promoting an understanding of the principles of theinvention, reference will now be made to the embodiment illustrated inthe drawings and specific language will be used to describe the same. Itwill nevertheless be understood that no limitation of the scope of theinvention is thereby intended, such alterations and furthermodifications in the illustrated device, and such further applicationsof the principles of the invention as illustrated therein beingcontemplated as would normally occur to one skilled in the art to whichthe invention relates.

Referring to FIG. 1, there is illustrated a gas turbine engine 20 whichincludes a fan section 21, a compressor section 22, a combustor section23, and a turbine section 24 that are integrated together to produce anaircraft flight propulsion engine. This type of gas turbine engine isgenerally referred to as a turbo-fan. One alternate form of a gasturbine engine includes a compressor, a combustor, and a turbine thathave been integrated together to produce an aircraft flight propulsionengine without the fan section. The term aircraft is generic andincludes helicopters, airplanes, missiles, unmanned space devices andany other substantially similar devices. It is important to realize thatthere are a multitude of ways in which the gas turbine engine componentscan be linked together. Additional compressors and turbines could beadded with intercoolers connecting between the compressors and reheatcombustion chambers could be added between the turbines.

A gas turbine engine is equally suited to be used for an industrialapplication. Historically, there has been widespread application ofindustrial gas turbine engines, such as pumping sets for gas and oiltransmission lines, electricity generation, and naval propulsion.

The compressor section 22 includes a rotor 25 having a plurality ofcompressor blades 26 coupled thereto. The rotor 25 is affixed to a shaft27 that is rotatable within the gas turbine engine 20. A plurality ofcompressor vanes 28 are positioned within the compressor section 22 todirect the fluid flow relative to blades 26. Turbine section 24 includesa plurality of turbine blades 30 that are coupled to a rotor disk 31.The rotor disk 31 is affixed to the shaft 27, which is rotatable withinthe gas turbine engine 20. Energy extracted in the turbine section 24from the hot gas exiting the combustor section 23 is transmitted throughshaft 27 to drive the compressor section 22. Further, a plurality ofturbine vanes 32 are positioned within the turbine section 24 to directthe hot gaseous flow stream exiting the combustor section 23.

The turbine section 24 provides power to a fan shaft 33, which drivesthe fan section 21. The fan section 21 includes a fan 34 having aplurality of fan blades 35. Air enters the gas turbine engine 20 in thedirection of arrows A and passes through the fan section 21 into thecompressor section 22 and a bypass duct 36. The term airfoil will beutilized herein to refer to fan blades, fan vanes, compressor blades,turbine blades, compressor vanes, and turbine vanes unless specificallystated otherwise in the text. Further details related to the principlesand components of a conventional gas turbine engine will not bedescribed herein as they are believed known to one of ordinary skill inthe art.

With reference to FIGS. 2-7, there are illustrated examples of castcomponents that could be produced from a casting mold system of thepresent system. The present disclosure is not intended to be limited tothe examples set forth in FIGS. 2-7, unless specifically set forthherein. More specifically, with reference to FIG. 2, there isillustrated a gas turbine engine blade 30. In one embodiment, the gasturbine engine blade 30 defines a single cast article having an internalflow path for the passage of cooling media. The internal cooling pathincludes a passageway with a plurality of heat transfer pedestals 37. Inone embodiment, the plurality of pedestals 37 are integrally formedbetween a pair of spaced walls. The pedestals are representative of thetypes of details that can be produced with the casting mold systems ofthe present invention. It is understood herein that the shape, size, anddistribution of the cooling pedestals are a function of heat transferparameters and design specific parameters. The FIG. 3 illustration isutilized herein merely to represent that pedestals having the followingdimensions are more particularly contemplated, and the dimensional sizesof one embodiment of the channels and pedestals are set forth inTable 1. However, it is understood that other pedestal and channel sizesand geometry's are contemplated herein.

TABLE 1 Length Width Height PEDESTAL 0.020-.050″ 0.020-.050″ 0.012-.020″CHANNEL N/A 0.012-.020″ 0.012-.020 

Referring to FIGS. 4 and 5, there is illustrated a sectional view of oneembodiment of a single piece multi-wall gas turbine engine componentproducible by the present system. Further, FIG. 6 illustrates theleading edge 43 of a spacecraft 42, which is producible with the systemof the present invention. While in FIG. 7 there is illustrated ahydraulic valve body 44 with internal fluid flow circuitry that depictsanother example of the types of cast products that could be producedwith the present system. The products illustrated herein are notintended to be limiting and other cast products are contemplated forproduction by the present system including, but not limited to art,jewelry, dental prosthesis, general prosthesis, custom hardware, golfclub heads, propellers, electronic packaging, tubes, valves and otheritems that have been traditionally investment cast for precisiontolerance and/or detail.

The methods and apparatuses of the present invention may be utilized toproduce single piece single cast components or multi piece castcomponents having microstructures that are commonly categorized asequiaxed, directionally solidified or single crystal. The preferredcasting mold system of the present invention is suitable for producingvirtually any type of cast metallic product, however in a more preferredembodiment it is particularly useful for producing thin walled singlecrystal structures. The cast structures may have many different shapes,sizes, configurations, and can be formed of a variety of metallicmaterials. For example, the system of the present invention allows thecasting of multi-wall structures with at least one wall having athickness less than about 0.03 inches. Further, in a preferredembodiment there can be formed very thin passageways within the caststructure/component and in a more preferred embodiment the very thinpassageways having a width of about 0.005 inches to about 0.015 inches.However, casting having passageways and wall thickness of other widthsand/or sizes and/or thickness are contemplated herein.

Gas turbine engine components are preferably formed of a superalloycomposition material. There are various types of superalloycompositions, such as but not limited to nickel based or cobalt basedcompositions, and the manufacture of such compositions are generallyknown to those skilled in the art. Most superalloy compositions ofinterest are complicated mixtures of nickel, chromium, aluminum andother select elements.

With reference to FIG. 8, there is illustrated the controlledsolidification of molten metal from a starter seed 300. The controlledsolidification of the molten metal is preferably used to produceproducts having a columnar grain or a single crystal microstructure.More specifically, the controlled solidification of the molten metal isaccomplished by the directional solidification of the molten metal.Directional solidification involves moving a solidification interfaceprogressively through a casting mold 301 filled with molten metal. Inmany circumstances, the metallic starter seed 300 is used to impartstrictly oriented crystallographic structure to the crystal being grown.The metallic starter seed 300 is placed within the casting mold 301 andthe introduction of the molten metal 302 into the mold 301 causes thestarter seed to melt back from an original surface 303 to a surfacedefined as the liquidus interface 304. In one form of the presentinvention, the melt back of the starter seed forms a puddle of liquidmolten metal from the starter seed. In one embodiment the depth of thepuddle is about 0.050 inches, however other puddle depths arecontemplated herein. A solidification zone 305 is positioned between theliquidus interface 304 and a solidus interface 306. As the thermalgradient moves vertically through the molten metal 302 in the mold 301,the material solidifies through the growth of dendrites 307 and thesolidification of the matrix material. In a single crystal process themolten material solidifies epitaxially from the unmelted portion of theseed 302.

With reference to FIG. 9, there is illustrated an integral mold 45 a forreceiving molten metal therein. In one embodiment the mold 45 a isformed by a free form fabrication technique generally known asthree-dimensional printing. In three-dimension printing systems aceramic material is deposited in layers to form a direct ceramic castingmold. The density of the layers can be varied by the number of dots perinch of material deposited. Information related to three-dimensionalprinting techniques is disclosed in U.S. Pat. Nos. 5,340,650, 5,387,380,and 5,204,055. A commercially available system for three-dimensionalprinting is available from Soligen Technologies, Inc. of North Ridge,Calif.

Integral mold 45 a is formed by the layerwise printing and binding ofceramic material, with each layer being bonded to an adjacent layer toform a ceramic shell for receiving molten metal therein. An apparatus 46a deposits the layers of material and binder to form the integral mold45 a based upon a design file. It is preferred that the design file begenerated from a computer aided design of the component. Preferably,mold 45 a is a thin walled shell having a main body 47 a with aninternal cavity for receiving molten metal to define a component uponsolidification. A portion of the internal metal receiving cavity isdepicted at 48 a. The integral mold 45 a includes a plurality of thinwalls 48 a, internal mold cores 50 a, and the internal metal receivingcavity. In one embodiment, the thin wall 49 a has a thickness in therange of about 0.005 inches to about 1.50 inches, and more preferablythe thin wall has a thickness of less than about 0.040 inches, and mostpreferably is about 0.020 inches. Integrally formed with the main body47 a are a bottom support member 51 a, a fill tube 52 a, a supportmember 53 a, and a wall member 54 a. In a preferred embodiment, the wallmember 54 a is defined by a web structure. Other integral mold stylesare contemplated herein and the present invention is not intended to belimited to the specific mold configuration and or material of FIG. 9.

With reference to FIGS. 10 and 11, there is illustrated one embodimentof a casting mold system 45 for receiving molten metal therein. Thecasting mold system 45 has a shell mold and cores produced integrallyfrom a photocurable ceramic resin, however the present invention is notlimited to integral casting molds. More particularly, in anotherembodiment a non-integral casting mold system has a separable core(s)and shell mold formed from the photocurable ceramic resin; thecomponents are subsequently mechanically coupled to form a casting moldsystem. The mold 45 is formed by a free form fabrication techniquegenerally known as selective laser activation (SLA). Selective laseractivation is based upon a stereolithography process that utilizesliquid resins that solidify when exposed to an energy dose. In thepresent invention a photocurable ceramic filled resin has at least onemonomer that is polymerized by the energy dose to form a polymer binderholding the ceramic particles together. The energy dose can be deliveredby any of a plurality of energy sources known to those skilled in theart. Preferably, the energy dose is defined by electromagneticradiation, and more preferably the energy dose is an ultraviolet lightemitted from a laser source having a wavelength of about 260 to 380nanometers, and most preferably is about 350 nanometers. However, lightof other wavelengths is contemplated herein. Commercially availablemachines for selective laser activation are available from 3D systems ofValencia, Calif. Further information related to selective laseractivation and stereolithography is disclosed in U.S. Pat. Nos.5,256,340, 5,556,590, 5,571,471, 5,609,812 and 5,610,824, which areincorporated herein by reference.

Integral mold 45 is formed by photopolymerization of the ceramic filledresin into layers of ceramic particles that are held together by apolymer binder. However, the present invention is not limited to aceramic filled resin and one alternate embodiment includes a metallicfilled resin. Further, the utilization of other fillers are contemplatedherein. In one embodiment a wall member layer is defined by a pluralityof adjoining portions of ceramic material that are indicatedschematically as lines 49 a, 49 b, 49 c, and 49 d. It is understoodherein that the number of adjoining lines in a layer and the number oflayers in the figure is purely representative and is not intended to belimiting herein. Preferably, an individual layer of the wall member isformed of between one and about five lines drawn by the energy beam inthe ceramic resin. More preferably, an individual layer of the wallmember is formed of two lines drawn by the energy beam in the ceramicresin. However, the present invention contemplates individual layershaving other numbers of individual lines in a layer.

While the wall member layers have been illustrated as being formed oflines it is understood that in alternate embodiment the wall member isformed of layers of spaced dots, and/or linked dots. The lines asdefined above for 49 a, 49 b, 49 c and 49 d could also be formed by aseries of dots. The series of dots are spaced relative to one another todefine a layer, and a plurality of layers is arranged to define a wallmember. In one embodiment the wall member has a grid structure of spaceddots that can contain the molten metal poured into a casting mold.Further, in another embodiment the grid structure can contain the moltenmetal poured into the casting mold while allowing the venting of gasesfrom the internal cavity in the mold through the wall member.

The width of the individual line(s) forming the layers is determined bythe width of the energy beam, and more preferably a laser defines theenergy beam. In one embodiment the width of energy beam is preferably inthe range of about 0.005 inches to about 0.025 inches and morepreferably is about 0.008 inches. However, an energy beams having awidth of about 0.001 inches is contemplated herein for producing veryfine detail in the casting mold system. Further, the ability to vary thewidth/size of the energy beam on command is also contemplated herein.More specifically, in one embodiment the size of the energy beam isvariable within a specific layer and/or between layers within thecomponent. In one commercially available stereolothography apparatus(SLA 250 from 3D Systems) the laser source is a He/Cd laser with 30 mwatts of power at the surface of the ceramic resin. However, otherstereolithography devices having different laser sources arecontemplated herein.

The generation of the casting mold system 45 is controlled by a datafile that defines the three dimensional shape of the casting moldsystem. With reference to FIG. 12, there is illustrated one embodimentof a system for creating the build file 1005 that determines how thecasting mold system is created. In act 1000 data defining parameters ofthe component (example a gas turbine blade) is collected and processedto define a specification for the component design. The data from act1000 is utilized in act 1001 to construct a component model using acomputer modeling system, and in one embodiment the computer modelingsystem is defined by a ComputerVision (CV) product. However, othermodeling systems are contemplated herein. The computer aided designmodel from act 1001 is processed in a mold modeling act 1002 to create amodel of the casting mold system. In one preferred embodiment the modelof the casting mold system is created by a Unigraphics system in act1002. A conversion act 1003 is utilized to convert the mold model,produced in act 1002, of the casting mold system to a specific fileformat, such as STL or SLC. Next the file from act 1003 is processed inact 1004 to create discrete two dimensional slices appropriate fordrawing the layers of the casting mold system and any required supports.In act 1005 the build file is completed which will drive the energysource in the stereolithography apparatus and produce the casting moldsystem.

In a preferred embodiment a scanning laser beam 46 b is directed by acomputer reading the data file and giving instructions to drawcross-sections of the three-dimensional shape on the quantity of ceramicfilled resin to so as locally polymerize the monomer within the ceramicfilled mixture. The irradiation of the monomer mixture with the laserforms a solid polymer gel. The integral mold 45 is preferably a thinshell having a main body 47 with an internal cavity for receiving moltenmetal therein for solidification to a product. A portion of the internalmetal receiving cavity is depicted at 48. The integral mold 45 includesthin walls 49, internal mold cores 50, and an internal metal receivingcavity. In one preferred form the thin wall 49 has a thickness less thanabout 0.060 inches, and more preferably has a thickness in the range ofabout 0.015 inches to about 0.060 inches, and most preferably has athickness of about 0.020 inches. However, casting molds having otherwall thickness are contemplated herein. In one preferred casting moldthere is formed with the main body 47, a bottom support member 51, afill tube 52, a support member 53, and a wall member 54. In the onepreferred embodiment, the wall member 54 is defined by a web structure.The illustrated casting mold of FIG. 10, is purely representative of thetypes of casting molds that can be fabricated with the presentinvention. More particularly, other casting mold configurations arecontemplated herein and the present invention is not intended to belimited to the specific mold shown in FIGS. 10 and 11.

With reference to FIG. 13, there is illustrated the casting mold system45 being fabricated within a stereolithography apparatus 500. Thestereolithography apparatus 500 is believed generally known by one ofordinary skill in the art and has been shown greatly simplified tofacilitate explanation of the method of making the casting mold system.A fluid containment reservoir 501, elevation-changing member 502, andthe laser 46 c comprise a portion of the stereolithography apparatus500. The reservoir 501 is filled with a quantity of the photocurableceramic filled resin from which the mold system 45 is fabricated.

In a preferred form of the present invention the elevation-changingmember 502 defines an elevator moveable to immerse the previously curedlayers of the casting mold system 45 in the ceramic filled resin to apredetermined depth. The ceramic filled resin recoating the uppermostcured layer with a layer of uncured ceramic filled resin. In a morepreferred embodiment the elevator is a computer controlled device thatincrementally lowers the fabricated casting mold in the bath of ceramicfilled resin in coordination with the rest of the process. In oneembodiment, the nominal thickness of the uncured resin coating is about0.004 inches to about 0.010 inches, and more preferably is about 0.004inches. However, other layer thickness are contemplated herein. Further,the thickness of the individual layer can be made to vary betweenlayers, or held to a substantially similar thickness between layers. Itis preferred that the system have provisions to insure a substantiallyuniform recoat thickness for those resins with a rather low viscosity.The utilization of the following techniques are contemplated to levelthe resin: a time delay to allow the resin to self level; and/orultrasonic processing to assist the resin in leveling; and/or amechanically assisted process to assist the resin in leveling. The laserbeam 46 b is driven by the data in the three-dimensional data file todraw cross-sections of the casting mold on the photocurable ceramicfilled resin. The drawing and recoating acts are continued until thegreen ceramic part has been completed.

With reference to FIG. 14, there is illustrated a casting mold system 45being fabricated in the stereolithography apparatus 500 at a buildorientation angle .theta.. The build orientation angle .theta. isselected so that the tangent of the angle for a given planar or nearplanar surface (or the collection of solid surfaces) to be built ismaximized. The build orientation angle .theta. is measured from an axisZ extending substantially perpendicular to the surface 503 of theceramic resin filled reservoir. One form of the present inventionorients the cross sections to minimize the drawing of relatively largeuninterrupted planar surfaces on the ceramic filled resin. The crosssections are defined and drawn substantially perpendicular to the axis Zand substantially parallel with the surface 503 of the resin. A buildplatform 505 is constructed within the reservoir 501 at the angle.theta. to orient the fabrication of the casting mold system 45 at thebuild orientation angle .theta.. In the preferred embodiment the buildorientation angle .theta. is an acute angle, and more preferably is anacute angle within a range of about 10 degrees to about 45 degrees, andmost preferably is about 45 degrees.

In simple two dimensional shapes the build orientation is relativelyeasy to define; for example a hollow cylinder would be preferably builtby fabricating a plurality of rings on each other. A hollow rectangulartube would be preferably built by fabricating a plurality of rectangularsections on each other to avoid having to build a relatively largeunsupported ceiling. A complex shape, like a cored casting mold systemfor a gas turbine engine blade, requires an analysis of all the ceramicsurfaces to calculate an optimum build orientation.

With reference to FIG. 15, there is illustrated an enlarged view of aplurality of cured layers 506, 507, 508 and 509 defining a portion ofthe casting mold system 45. The cured layers in a preferred aluminafilled resin have a thickness within a range of about 0.002 inches toabout 0.008 inches, and more preferably have a thickness of about 0.004inches. The cured layers in a preferred silica filled resin have athickness within a range of about 0.002 inches to about 0.020 inches,and more preferably have a thickness of about 0.006 inches. However,other cured thickness are contemplated herein. Further, the individualcured layers can be of the same or different thickness. However, it ispreferred that each of the individual curved layer have a substantiallyuniform thickness.

The particle size for the individual ceramic particles 510 arepreferably less than about 20 microns, and more preferably are within arange of about 0.1 microns to about 3.0 microns. The control of theparticle size allows for the fabrication of finer detail andsubstantially smooth surfaces in comparison to other known techniquesfor making ceramic casting mold systems.

The casting mold system is a layered built structure and FIGS. 14 and 15have been exaggerated to emphasize the individual cured layers. Theindividual layers are formed of a plurality of ceramic particles 510 anda polymer binder 511 that holds the particles within an individual layertogether. In one embodiment the polymer binder 511 extends between theadjacent layers to couple the cured layers together. Each of a pair ofadjacent cured layers, such as layers 506 and 507 have a respectivecross-sectional area abutting at a layer line 600. In a preferredembodiment there is joining between the complimentary surfaces of theadjacent layers in the range of about 10% to about 100% of each of therespective surfaces. More preferably, in one embodiment of the silicafilled resin there is joining between the complimentary surfaces of theadjacent layers at about 10 percent of the respective surfaces; and inone embodiment of the alumina filled resin there is joining between thecomplimentary surfaces of the adjacent layers at about 50 percent of therespective surfaces. However, in some alternate embodiments, theadjacent cured layers are not joined together by the polymer binder. Thelayers are held one against the other by mechanical and/or secondarychemical reactions.

The thickness of the layers depends upon the thickness of the recoateduncured layer and the depth of penetration of the laser beam. Morespecifically the cure depth is indicated as the cured layer thicknessplus an overcure depth. In one embodiment the overcure depth is about50% of the cured thickness layer directly beneath the layer being cured.In one embodiment a substantial overcure is required in the aluminafilled resin to minimize the subsequent green delamination or layerseparation. However, embodiments of the present invention utilize anovercure cure depth within a range of about 10% to about 150% of thecured layer. However, the present invention is not limited to the abovecure depths and other cure depths are contemplated herein.

The ceramic filled resin includes a sinterable ceramic material, aphotocurable monomer, a photoinitiator and a dispersant. The ceramicfilled resin is particularly adapted for use in stereolithography toproduce a green ceramic mold that resists cracking when sintered. Thefilled resin is prepared by admixing the components to provide a filledresin having viscosity of less than about 4,000 cPs, more preferablebetween about 90 cPs and about 3,000 cPs and most preferably betweenabout 100 to about 1000 cPs. The resulting filled resin has a solidsloading of about 40% to about 60% volume solids in the resin. Further,in one embodiment the filled resin has a density of between about 1.0 toabout 4.0 g/ml, more preferable between about 1.5 and 2.5 g/ml.

The sinterable ceramic material for use in this invention can beselected from a wide variety of ceramic materials. Specific examplesinclude alumina, yttria, magnesia, silicon nitride, silica and mixturesthereof. The sinterable ceramic material is included in the filled resinat about 50 volume percent (vol. %) based upon the total volume of thefilled resin. Expressed in other terms, the filled resin includes about50 to about 85 weight percent (wt %) of the sinterable ceramic material,most preferably about 65 to about 80 wt % based upon the total weight ofthe filled resin.

In one example silica is selected as the sinterable ceramic material.Silica can be provided as a dry powder having an average particle sizesuitable for sintering to provide a cured mold in accordance with thisinvention. Preferably the powdered silica is selected to have an averageparticle size of about 0.5 microns to about 20.0 microns and, morepreferably about 1.0 micron to 20.0 microns, and most preferably about1.0 micron to about 5.0 microns. Preferably, the amount of silica isbetween about 50.0 wt % and about 72.0 wt % based upon the total weightof the filled resin.

The monomer is selected from any suitable monomer that can be induced topolymerize when irradiated in the presence of a photoinitiator. Examplesof monomers include acrylate esters and substituted acrylate esters. Acombination of two or more monomers may be used. Preferably at least oneof the monomers is a multifunctional monomer. By multifunctional monomerit is understood that the monomer includes more than two functionalmoieties capable of forming bonds with a growing polymer chain. Specificexamples of monomers that can be used with this invention include1,6-hexanediol diacrylate (HDDA) and 2-phenoxyethyl acrylate (POEA). Thephotocurable monomers are present in an amount between about 10 to about40 wt %, more preferably about 10 to about 35 wt %, and most preferablyabout 20-35 wt % based upon the total weight of the filled resin.

The dispersant is provided in an amount suitable to maintain a uniformcolloidal suspension of the silica in the filled resin. The dispersantcan be selected from a wide variety of known surfactants. Preferreddispersants include ammonium salts, more preferably tetraalkyl ammoniumsalts. The tetraalkyl groups can include a variety of substituents.Specific examples of dispersants for use in this invention include, butare not limited to: polyoxypropylene diethyl-2-hydroxyethyl ammoniumacetate, and ammonium chloride. Preferably, the amount of dispersant isbetween about 1.0 wt % and about 10 wt % based upon the total weight ofthe ceramic within the filled resin.

The initiator can be selected from a number of photoinitiators known tothose skilled in the art. The photoinitiator is selected to be suitableto induce polymerization of the desired monomer when irradiated.Typically the selection of a photoinitiator will be dictated by thewavelength of radiation used to induce polymerization. Preferredphotoinitiators include benzophenone, trimethyl benzophenone,1-hydroxycyclohexyl phenyl ketone, isopropylthioxanthone, 2-methyl-1-[4(methylthio)phenyl]-2-morpholinoprophanone and mixtures thereof. Thephotoinitiator is added in an amount sufficient to rapidly polymerizethe monomers when the filled resin is irradiated with radiation ofappropriate wavelength. Preferably the amount of photoinitiator isbetween about 0.05 and about 5 wt % based upon the total weight of themonomer within the filled resin.

In an alternate form of the ceramic filled resin a quantity of anonreactive diluent is substituted for a quantity of the monomer.Preferably, the amount of substituted nonreactive diluent is equal tobetween about 5% and about 20% (by weight or volume) of the monomer inthe resin. An illustration of a given ceramic resin composition requires100 grams of a monomer that in the alternate form will replace about5-20 wt % of the monomer with a nonreactive diluent (i.e. 95-80 grams ofmonomer+5-20 grams of nonreactive diluent). The nonreactive diluentincludes but is not limited to a dibasic ester or adecahydronaphthalene. Examples of dibasic esters include dimethylsuccinate, dimethyl glutarate, and dimethyl adipate, which are availablein a pure form or a mixture.

The filled resin is prepared by first combining the monomer, thedispersant and the sinterable ceramic to form a homogeneous mixture.Although the order of addition is not critical to this inventiontypically, the monomer and the dispersant are combined first and thenthe sinterable ceramic is added. Preferably the sinterable ceramicmaterial is added to the monomer/dispersant combination in increments ofabout 5 to about 20 vol. %. Between each incremental addition of theceramic material, the resulting mixture is thoroughly mixed by anysuitable method, for example, ball milling for about 5 to about 120minutes. When all of the sinterable ceramic material has been added, theresulting mixture is mixed for an additional amount of time up to 10hours or more. The photoinitiator is added and blended into the mixturejust prior to irradiation of the resin, preferably not more than about 2hour prior to irradiation.

A preferred silica filled resin comprises about 67.1 wt % silica, about31 wt % monomer, about 1.37 wt % dispersant, and about 0.619 wt %photoinitiator. The wt % are based upon the total weight of the silicafilled resin. A preferred alumina filled resin comprises about 78.2%alumina, about 20.1 wt % monomer, about 1.56 wt % dispersant, and about0.101 wt % photoinitiator.

With reference to Table II there is set forth a preferred silica filledresin and a preferred alumina filled resin.

TABLE II wt/g vol wt % vol % Alumina 1980 500 78.2 48.0 Monomer 510 50020.1 48.0 Dispersant 39.6 38.8 1.56 3.73 Photoinitiator 2.55 2.32 0.1010.223 Total 2532 1041 100% 100% Silica 2210 1000 67.1 48.5 Monomer 10201000 31.0 48.5 Dispersant 44.2 43.33 1.37 2.14 Photoinitiator 5.10 4.6360.619 0.899 Total 3279 2048 100% 100%

In an alternate embodiment, the ceramic filled resin is defined as aduplex curing resin. The duplex curing resin utilizes two types ofinitiators to cause the polymerization of the monomer. In a preferredform there is one photoinitiator for UV light curing, and anotherinitiator for thermal curing. One example of an initiator for thermalcuring is benzoyl peroxide or AIBN. AIBN comprises2-2′-azo-bis-isobutyrylnitrile. However, the initiator for thermalcuring can be selected from a number of other initiators known to thoseskilled in the art.

With reference to FIG. 16, there is illustrated an alternate embodiment55 of the thin wall structure 49. The composite wall structure 55comprises a pair of spaced thin outer walls 56 and 57 with a pluralityof internal wall members 58 connecting therebetween. A plurality ofcavities 63 is formed in the wall structure 55 and in one embodimentincludes an internal core structure 59. In a preferred embodiment, theinternal core structures 59 are hollow and integrally connected to thewalls that define the cavity 63.

With reference to FIG. 17, there is illustrated a third embodiment 60 ofthe thin wall structure 49 of the integral mold 45. Wall structure 60includes a pair of spaced thin outer walls 61 formed with and coupled toa porous inner member 62. The density of the inner member 62 ispreferably less than the density of the outer walls 61. Wall structure60, 55, and 49 can be used together or separately as required by thedesign. It is understood herein that wall structures 49, 55, and 60 arepurely illustrative of wall structures of the present invention and arenot intended to be limiting in regards to other designs for compositewall structures.

Referring to FIGS. 18 and 19, there are illustrated alternate forms 65and 70 respectively of a portion of the mold core 50. Mold core 65 hasan integral thin wall structure 66 with an internal hollow corestructure 67 formed therewith. Formed between the outer wall structure66 and the internal hollow core structure 67 is a porous structure 69.Mold core 70 includes a thin wall 71 with an internal hollow core 72formed therewith. A plurality of reinforcing ribs 74 are formed betweenthe outer wall 71 and the internal hollowcore 72. The configurations ofthe mold cores 50, 65, and 70 are not intended to be limiting herein andother designs of mold cores are contemplated herein.

Referring to FIGS. 20 and 21, there is illustrated another embodiment ofa green casting mold system. The casting mold 525 is substantiallysimilar to the previously described casting mold system 45. Morespecifically, the casting mold system 525 has an integral ceramic shell526 and ceramic core 527. The volume 528 between the core ceramic shell526 and the core 527 defines the component to be formed from a moltenmetallic material. Preferably, the volume 528 includes no supportingstructure extending therein to interfere with the receipt of moltenmetal. More specifically, in a more preferred embodiment the drawing ofthe cross-sections does not draw any structure within the volume 528.However, in another embodiment of the present invention the fabricationprocess produces supporting structure within the volume 528 that can beremoved without damaging the ceramic shell 526 and/or the core 527. In apreferred form the inner wall surface 529 of the ceramic shell 526 andthe outer surface 530 of the ceramic core 527 as formed aresubstantially smooth. The wall surface will be defined as either astepped surface which is defined by a portion of a plurality of abuttinglayers, or a flat surface which is defined by a surface of a singlelayer. More specifically, the green state components have an as formedsurface finish for a stepped surface within a range of about ten micronsto about 30 microns, and an as formed surface finish for a flat surfacewithin a range of about 0.5 microns to about 10 microns.

In one embodiment of the casting mold system 525 the core 527 issubstantially hollow. A thin outer wall shell 540 has a plurality ofspaced inner wall members 541 integrally formed therewith. It iscontemplated herein that cores having a solid configuration and asubstantially hollow configuration are within the contemplation of thepresent invention.

Referring to FIG. 22, there is illustrated a partial sectional viewtaken along line 22-22 of FIG. 20. The ceramic core 527 has a passageway532 formed therein that is adapted for the receipt of molten metal. Morespecifically, there is a plurality of spaced passageways 532 formed inthe ceramic core 527 for the receipt of molten metal. The passageways532 allow the casting of details in the component. In a preferredembodiment each of the passageways 532 has an as formed width/diameterin the range of about 0.005 inches to about 0.030 inches, and morepreferably defines a width/diameter less than about 0.020 inches, andmost preferably defines a width/diameter of about 0.010. FIG. 23 is anillustration of another embodiment of an integral multi-wall ceramiccasing mold system.

With reference to FIG. 24, there is schematically shown a casting moldsystem 45 positioned within a furnace 550. The furnace provides the heatrequired for substantially burning out the polymer binder from a greenceramic casting mold system and sintering the ceramic particles. In apreferred form the casting mold system is oriented within the furnace soas to minimize the number of individual layers resting on the surface551 of the furnace. A firing schedule for a green ceramic mold systemincludes heating the mold within the furnace from a normal roomtemperature at a rate of about 0.1 degrees centigrade per minute toabout 5.0 degrees centigrade per minute to a first temperature of aboutthree hundred degrees centigrade to about five hundred degreescentigrade. Thereafter holding the maximum temperature for a time rangeof about zero hours to about four hours to burn out the polymer binder.After the heating portion the densified casting mold system is subjectedto a sintering schedule. The sintering schedule increasing thetemperature within the furnace from the first temperature at a rate ofabout 5.0 degrees per minute centigrade to about 10.0 degrees per minutecentigrade to a second temperature within a range of about 1300 degreescentigrade to about 1600 degrees centigrade. The casting mold system isheld at the second temperature for a time range of about zero hours toabout four hours. The casting mold system is then cooled to roomtemperature at a rate of about 5.0 degrees centigrade per minute toabout 10.0 degrees centigrade per minute. The casting mold system ispreferably sintered to a density greater than about 70%, and morepreferably the casting mold system is sintered to a density within arange of about 90-98%. Most preferably, the casting mold system issintered to a substantially full density. In one embodiment the sinteredceramic casting mold system is about 99 wt % ceramic particles, and morepreferably about 99 wt % alumina

A preferred firing schedule for an alumina based green ceramic moldsystem includes heating the mold within the furnace from a normal roomtemperature at a rate of about one degree centigrade per minute to afirst temperature of about 300 degrees centigrade and holding at thefirst temperature for about four hours. Thereafter increasing thetemperature from the first temperature to a second temperature of about500 degrees centigrade at a rate of about one degree centigrade perminute. Holding at the second temperature for about zero hours.Increasing the temperature at a rate of about ten degrees centigrade perminute from the second temperature to a third temperature of about 1550degrees centigrade. Holding at the third temperature for about twohours. The casting mold system is then cooled from the third temperatureto room temperature at a rate of about five degrees centigrade perminute.

A preferred firing schedule for a silica based green ceramic mold systemincludes heating the mold within the furnace from a normal roomtemperature at a rate of about one degree centigrade per minute to afirst temperature of about 300 degrees centigrade and holding at thefirst temperature for about four hours. Thereafter increasing thetemperature from the first temperature to a second temperature of about500 degrees centigrade at a rate of about one degree centigrade perminute. Holding at the second temperature for about zero hours.Increasing the temperature at a rate of about ten degrees centigrade perminute from the second temperature to a third temperature of about 1500degrees centigrade. Holding at the third temperature for about twohours. The casting mold system is then cooled from the third temperatureto room temperature at a rate of about five degrees centigrade perminute.

The integral casting molds 45 and 45 a are produced by differentprocesses and while they do have different properties, they both form aceramic shell for receiving molten metal therein. However, it isunderstood that in another form of the present invention the ceramicsshell can receive other material for solidification besides moltenmaterial. While the forming of a ceramic mold by three-dimensionalprinting and selective laser activation have been discussed herein, thepresent casting inventions are not intended to be limited to these typesof molds, unless specifically stated. For example, a mold produced withconventional techniques of cores and patterns which are shelled bydipping in a ceramic slurry, resin shell molds, or sand molds are alsocontemplated herein. Hereinafter, the term casting mold will be referredto generically as casting mold 45 and is intended to include all typesof ceramic casting molds, unless specifically stated to the contrary.

With reference to FIG. 25, there is illustrated one embodiment of theintegral casting mold 45. The completed integral mold 45 has a basemember 51, a top member 77, and a main body 47 extending therebetween.Support member 53 extends between the bottom member 51 and the topmember 77, while the fill tube 52 extends from the fill inlet 78 to abottom portion 47 a of the main body 47 and is in fluid communicationwith the internal metal receiving cavity of the mold. Preferably thebase member 51 is defined by a ring structure. A vent 79 is formed inthe integral mold 45 and opens into the internal metal receiving cavityto allow gaseous material to enter and leave the mold, aid in materialremoval, and aid in casting fill. It is understood herein that inalternate embodiments the integral casting mold 45 may be of a differentconfiguration and may not include features such as the base memberand/or the top member.

In one embodiment, the top member 77 defines a toothed ring or diskstructure disk contactable with the container 80. Preferably, theintegral mold 45 has been designed to minimize the quantity of materialneeded to produce it, and therefore its thin shell causes it to resemblethe contour of the product being cast therein. In the present example,the mold 45 resembles a gas turbine blade, however, other shapes arecontemplated. Further, the integral mold could be formed such that itsouter surface does not conform to the shape of the product/componentbeing cast within the internal cavity.

In the designing and forming of the integral mold 45 there are manyparameters to consider including: (1) the desired strength and stiffnessof the mold; (2) the speed at which the mold can be created; (3) theability for the cores within the mold to crush as the metal solidifies;(4) the rate of the heating/cooling during the casting; (5) theremoval/leach speed of the cores; and, (6) restraint of the castingduring cooling after solidification. The crushability of portions of themold as the molten metal solidifies around it can be addressed by thevariation in densities, structures and the porosity of the components.For example with reference to FIGS. 18 and 19 there is illustrated corestructures 65 and 70 that have a porous structure 68 and a reinforcingweb structure 74 that will partially collapse/give as molten metalsolidifies therein.

With reference to FIG. 26, there is illustrated a mold container 80 andintegral mold 45 positioned in a furnace 81. While the mold container 80has been illustrated with the integral mold 45 positioned therein, it isunderstood that other types of molds may also be positioned within themold container 80. The mold container 80 is designed and constructed tocontain the integral mold 45, during the casting process. An outer wallmember 82 of the container 80 has an opening therethrough that is sizedto provide an interference fit between an inner surface of the moldcontainer and the outer surface 51 a of the base member 51 and a portionof the outer surface 77 b of the top member 77. In one embodiment, themold container 80 is defined by a thick walled fibrous ceramic tube thatis shrink fitted over the bottom member 51 and the top member 77. Theterm tube, as used herein, defines a hollow member and is not intendedto be limited to a hollow cylindrical structure, unless specificallystated. The container in an alternate embodiment includes an integralbottom wall member that generally defines a cup shaped container.However, other shapes for the container are contemplated herein.Further, in an alternate embodiment the container and the mold are notin an interference fit.

In a preferred embodiment the mold container 80 is defined by anelongated cylindrical shaped tube. In one form the wall thickness forthe outer wall member 82 is within a range of about 0.010 to about 1inch, and more preferably is about 0.5 inches. However, other wallthickness are contemplated herein. The outer wall member 82 being formedof a ceramic material that has been selected for specific heat transferrequirements. In one embodiment, the member transfers the heat from itsouter surface 82 a quickly so as to facilitate handling, while inanother embodiment the member has been designed to insulate the integralmold 45. Materials such as, but not limited to, porous ceramics, ceramicfibermatts, metals, and metals with thermal barrier coatings arecontemplated herein for the outer wall member 82.

At least one supporting members 83 is positioned within the spacebetween the inner surface 84 of the outer wall 82 and the outer surface45 a of the integral mold 45. The supporting member provides support forthe thin walled integral mold 45 during the casting process. Thereinforced mold container 80 allows the delivery of the molten metal athigh pressures to a thin shell mold. In one embodiment molten metalpressures within the range of about three inches to about twenty-fourinches of nickel are contemplated herein for use with the reinforcedthin walled integral mold. However, other molten metal pressures arecontemplated herein.

In a preferred embodiment, the supporting member 83 is defined by aplurality of supporting members, and more preferably is defined by aplurality of ceramic media members. In one embodiment, the plurality ofsupporting members having a size within the range of about 0.010 inchesto about 0.100 inches and are defined as a spherical/ball. However,other sizes are contemplated herein. The plurality of supporting membersfill the space within the mold container 80 and abut the outer surface45 d of the integral mold. It is understood that the shape of theplurality of supporting members includes, but is not limited to, tablet,spherical, or fibrous. Moreover, in an alternate embodiment of thepresent invention, the supporting member within the mold container canbe defined by: a continuous ceramic material formed between the innersurface 84 of the outer wall 82 and the outer surface 45 d of integralmold 45; a ceramic foam such as alumina, mullite, silica, zirconica, orzircon. The web structure 54 is designed and constructed to minimize theamount of material utilized to create a bottom wall member forpreventing the passage of the plurality of support members 83 from thecontainer 80. However, other structures such as but not limited to asolid wall are contemplated herein. The plurality of ceramic supportingmedia 83 are readily removable from the containers for reuse and/orrecycling.

With reference to FIG. 27, there is illustrated the mold container 80which further includes a supplemental mold heater 91. Supplemental moldheater 91 is controlled to add energy as needed during thesolidification of the molten metal and growth of the crystal within theintegral mold cavity. In one form the supplemental mold heater 91 iscoupled to the inner surface 84 of the outer wall 82 of the moldcontainer 80 and is positioned at the top portion of the mold container80. However, other locations along the mold container are contemplatedherein.

With reference to FIG. 28, there is illustrated a cross sectional viewof the mold container 80 with the integral mold 45 located therein. Thecross section has been taken through line 28-28 of FIG. 27, whichcorresponds, to an airfoil-forming portion of the internal cavity forreceiving a molten metal therein. The plurality of supporting members 83abut the outer surface 45 d in order to support the thin wall 49 duringthe pouring of molten metal within the cavity 48. The plurality ofsupporting members 83 have spaces 94 therebetween which serve as aninsulator to prevent the transfer of heat from the integral mold 45 tothe outer wall 82. Further, the plurality of supporting members 83define a discontinuous heat transfer path to the outer wall 82 of thecontainer. The plurality of members 83 function to retain the heatradiating from the integral mold 45 so as to help maintain a desiredtemperature for the integral mold 45.

With reference to FIG. 29, there is illustrated the mold container 80with the integral casting mold located therein. A localized mold heater93 is positioned within the space defined between the outer wall 82 ofthe container 80 and the outer surface 45 a of the mold 45 so as to heata portion of the integral mold 45. The utilization of a localized moldheater 93 within the mold container can be adjacent or proximate anyportion of the outer surface 45 a of the mold 45. It is contemplatedthat the localized mold heater 93 can be continuous along a surface, ordiscontinuous along a surface or spaced from a surface as required byparameters related to the mold design. The depiction of the supplementalmold heater in FIG. 29 is not intended to be limiting therein.

With reference to FIGS. 30 and 31, there is illustrated a method andapparatus for removing unbonded material 400 from within the internalcavity of the integral mold 45. While the process is illustrated with afree form fabricated mold having a plurality of layers of a materialbonded together, it is also contemplated as being useful for other moldstructures having unbonded particles located within a metal receivingcavity. The unbonded material relates to powders, particulate, and othermaterial that is not bonded to the walls of the integral mold 45 withinthe cavity 48. In one form, the process for removing unbonded materialfrom within a casting metal receiving cavity relates to a mold producedby the printing and binding of layers of powder to form a direct ceramiccasting mold. In another embodiment the integral mold 45 has been heatedto dry the unbonded materials within the cavity. In another form, theprocess for removing unbonded material from within a casting metalreceiving cavity is related to a mold produced by a selective laseractivation technique to form a ceramic shell. The unjelled slurry may bedried and removed or removed in an undried state.

The mold container 80 with integral mold 45 is positioned at aninclination angle .theta. and rotated about an axis Z. In the preferredembodiment, the angle .theta. is an acute angle within the range ofabout 5 to about 90 degrees, and more preferably, the angle .theta. isabout 15 degrees. However, in the alternate embodiment the angle .theta.is variable. Rotation and movement of the integral mold 45 causes theunbonded material 400 to be dislodged from the walls defining theinternal cavity and passed through an exit aperture 101 that is incommunication with the internal cavity, and into a bin 104. In analternate embodiment the integral mold has a plug (not illustrated) putinto the exit aperture 101 after the unbonded material 400 has beenremoved from the internal cavity. In a preferred embodiment, the exitaperture 101 is sized to receive a metallic starter seed utilized duringthe casting operation to facilitate a specific crystallographicstructure and/or speed solidification.

In one form, the sprocket 77 of the integral mold 45 is engaged with adrive 102. The drive 102 is driven such that the container is revolvedat speeds in the range of about 0.1 to 2 revolutions per minute, andmore preferably rotates at a speed of about ⅓ revolutions per minute,however, other speeds are contemplated herein. The dwell time for whichthe integral mold is subjected to rotation is in the range of about 15minutes to about 2 days and more preferably is about 2 hours. However,other dwell times are contemplated herein. The containers 80 pass alonga container support 103 in the direction of arrow P as they are rotatedabout axis Z. A container spacer 105 is positioned between pairs of moldcontainers 80 so as to prevent contact between the containers. Further,the containers 80 may be inverted as necessary to facilitate removal ofthe material 400 from the internal cavity, and a fluid scrubbing can beintroduced into the internal cavity to facilitate material removal. Theintroduction of fluids within the internal cavity can occur in thenormal or inverted state.

The integral mold 45 is subjected to a thermal processing operationprior to the receipt of molten metal within its internal cavity. Theintegral mold 45 whether formed by the three-dimensional printing or theselective laser activation process, has a green state strength that isnot sufficient for the casting process and therefore to increase it'sstrength it has been fired as previously discussed. In some moldconstructions it is necessary to burn out polymers and other materialspresent in the green state mold. More specifically, in the case of theintegral mold which is formed by the selective laser activation process,it is necessary to burn out the polymers within the green phase mold.The mold produced by the three-dimensional printing techniques generallydo not require the burn out process as there are not significantmaterials to be removed from the green state integral mold 45. Lastly,the mold must be preheated to the appropriate temperature, which ischosen to facilitate the growth of the microstructure desired. In thecase of a columnar grain structure the temperature desired to preheatthe mold is about 2700 degrees Fahrenheit and in the case of a singlecrystal casting the temperature desired for the mold preheat is about2800 degrees Fahrenheit.

In one form of the present invention, it is preferred to have anintegrated thermal processing operation for the integral mold 45. Theintegrated thermal processing will include firing the green state mold45, burning out the unwanted materials in the green state mold, andpreheating the mold to the desired temperature necessary for casting thedesired microstructure. The molds after the firing and sinteringoperation are then cooled, inspected, repaired as necessary and preparedfor casting. Thereafter, the mold is elevated to the temperature desiredfor preheating the mold. In a more preferred form, each of these stepsoccur in the same furnace in a substantially continuous fashion.Elimination of thermal cycling of the mold will enhance the ability tocast hollow structures with intricate/delicate passages.

With reference to FIG. 32, there is depicted a functional representationof a casting apparatus 420 for delivering a charge of molten metal 108to a casting mold, such as the mold container 80 with integral mold 45therein. The present invention contemplates a casting apparatus thatfunctions in a substantially continuous or a batch processing fashion.The casting mold utilized with the casting apparatus is not intended tobe limited herein to a specific mold style or construction. The castingapparatus includes a precision molten metal delivery system 106 that islocated within a furnace 107. In a preferred form of the presentinvention, the furnace 107 is defined by a dual chambered vacuumfurnace. However, it is understood that other types of furnaces such asair melt or pressurized casting furnaces are contemplated herein. Theprecision molten metal delivery system for discharging a quantity ofmolten metal to the mold 80 is located within an environmentallycontrolled chamber 109. The molten metal delivery system 106 is fedmolten metal from beneath the surface of the molten metal within acrucible 111. A supply of metal material 110 passes into the chamber 109and is melted within the crucible 111. The supply of metal materialwithin the crucible is heated to a super heated state, and for thealloys associated with casting turbine engine components the super heatis in the range of 350-400.degree. Fahrenheit. However, it is understoodthat other super heat temperatures for these alloys and other types ofmetals is contemplated herein.

In one embodiment, the control chamber 109 is supplied with an inert gas112 that forms a shield and/or membrane to slow surface vaporization ofthe molten metal within the crucible 111. Dispensing of the molten metalis controlled by a pressure differential between the molten metaldelivery system 106 and the mold 80. In one embodiment, the discharge ofmolten metal is controlled by the application of a positive pressure tothe surface of the molten metal, which in turn drives a quantity ofmolten metal from the crucible 111 into the mold 80. The mold 80 ispositioned within a second chamber of the vacuum furnace and is at alower pressure than the molten metal delivery system 106.

With reference to FIGS. 33 and 34, there is illustrated one embodiment115 of the casting apparatus of the present invention. The castingapparatus 115 includes a dual chambered vacuum furnace 116 with an upperchamber 117 and a lower chamber 118 separated by a wall 114. Thecreation of a pressure difference between the chambers is utilized todeliver the charge of molten metal to the mold. A mold entry port 119allows for the introduction and removal of casting mold containers, suchas 80, from the lower chamber 118. In one form of the present invention,the mold entry port 119 defines a fluid tight interlock that enables themaintenance of a vacuum environment within the lower chamber 118 as themold container 80 is removed or inserted into the lower chamber.Positioned within the lower chamber is a rotatable fixture 121 forholding the molds 80 during the pouring and solidification of the moltenmetal. A starter seed 421 is positioned with the mold container 80 andcoupled with the fixture 121. In a preferred form of the presentinvention, the fixture 121 includes a heat transfer apparatus in heattransfer communication with the starter seed 421 to withdraw energy fromthe starter seed so as to directionally solidify the molten metal withinthe mold 45.

A metal material feeder 120 allows for the introduction of unmeltedmetal material 137 into the melting crucible 122 located within upperchamber 117. In one form of the present invention, the unmelted metalmaterial 137 is in bar form and is passed into the crucible withoutinterrupting the operation of the casting apparatus 115. In thepreferred embodiment, the melting crucible 122 defines a refractorycrucible in which the metal material is inductively heated by aninduction heater 123. It is understood that other forms of heaters, suchas but not limited to levitation and resistant, are contemplated hereinfor melting and elevating the temperature of the metal material withinthe crucible 122. The crucible 122 is designed and constructed to hold aquantity of molten metal from, which is removed smaller charges ofmolten metal to fill the individual molds. The quantity of molten metalthat the crucible can hold is preferably in the range of about 5-200pounds, and more preferably is about 50 pounds. However, as discussedpreviously the crucible can have sufficient capacity for a continuousprocess or be sized for an individual single pour. In one embodiment,the crucible holding a reservoir of molten metal reduces temperaturefluctuations related to the delivery of charges of molten metal and theintroduction of unmelted metal material into the crucible for melting.The molten metal 124 within the melting crucible 122 passes into amolten metal dispensing system. In one embodiment, the molten metaldispensing system defines an apparatus for the precision pouring ofmolten metal through a nozzle 253 to a precision located input 78 of thefill tube 52. A more detailed description of the molten metal dispensingsystem 125 and alternate embodiments for dispensing molten metal fromthe crucible 122 will be discussed below.

In one embodiment of the present invention, the rotatable fixture 121 isliquid cooled and located within the lower chamber 118 of the vacuumfurnace. The heat transfer system is coupled with each of the castingmolds 45 and maintains a heat transfer pathway during the solidificationof the molten metal. The rotatable fixture includes a plurality of moldcontainer holders 129. In the embodiment of FIG. 34, the mold containerholders 129 are spoke members, however, other structures arecontemplated for holding the molds as they are filled with molten metaland solidified into the particular microstructure desired. The moldcontainer 80 is rotated to a position 131 wherein the filler tubes inlet78 is in alignment with the pouring nozzle 253.

With reference to FIG. 35, there is illustrated an alternate embodiment135 of the casting apparatus. The casting apparatus 135 is substantiallysimilar to casting apparatus 115 and like features will be indicated bylike feature numbers. The major distinction between the castingapparatus 135 and the casting apparatus 115 is the inclusion of a seal136 for forming a fluid tight seal with the unmelted metal stock 137 asit moves into the upper chamber 117. In a preferred form, the seal 136abuts an outer surface 137 a of the unmelted metal stock 137. Theadvancement of the metal stock 137 into the upper chamber 117 in thedirection of arrow S will cause an increased pressure acting on themolten alloy 124 in the crucible 122. The increasing of pressure and/orforce on the molten metal 124 can be attributed to the advancement ofthe metal stock 137 into the molten metal 124 and/or by increasing thepressure of an inert gas 127 supplied through the valve 126. In apreferred form the inert gas is argon or helium and the pressuredifference associated with the inert gas is 60 milli-torr.

Referring to FIG. 36, there is illustrated another embodiment 140 of thecasting apparatus of the present invention. The casting apparatus 140 issubstantially identical to the casting apparatus 135 with like featurenumbers indicating like features. The casting apparatus 140 provides forthe positioning of nozzle 253 into the inlet 78 of the metal fill tube52. The coupling of the nozzle to the fill tube enables increased headpressure to improve fill. Further, in one form the system is applicableto control molten metal pressure over time. Therefore, upon discharge ofthe molten metal from the nozzle there is a confined passageway that themolten alloy passes through to the fill tube 52. In order to effectuatethe mating of the nozzle 253 with the inlet 78 of the mold container 80,the rotatable fixture 121 is moveable vertically. The fixture 121 islowered to receive the mold container 80 from the mold changer 130 andthen raised to position the mold container in a seating relationshipwhen it is desired to pour the charge of molten metal into the mold.

Referring to FIG. 37, there is illustrated a casting apparatus 145 thatis substantially similar to the prior casting apparatuses of FIGS.33-36, with the notable difference being the capability of castingapparatus 145 to handle larger casting molds. Casting apparatus 145allows for the introduction of a larger casting mold 525 through adoorway 146 adjoining the lower chamber 528. In one embodiment, themolten metal 124 is delivered from a molten metal dispensing system intothe inlet 523 of the mold cavity 525. Thereafter, the mold 522 iswithdrawn from the pour position with chamber 528 by an elevator 548.

With reference to FIG. 38, there is illustrated one embodiment of a heattransfer apparatus 150 for causing heat transfer with a metallic starterseed 151. In a preferred form the thermal gradient across the seed isvaried over time. More particularly, in one embodiment the thermalgradient is low during nucleation and substantially higher during thegrowth of the crystal. The thermal gradient in one form is greater thanabout 550.degree. F./inch at the liquid to solid interface. In oneembodiment the starter seed 151 has a length ‘B’ within a range of about0.25 inches to about 3.00 inches, however, other starter seeds lengthsare contemplated herein. Heat transfer apparatus 150 has a pair of jaws152 that are normally mechanically biased to place a surface 154 of thejaws in an abutting thermally conductive arrangement with the body ofthe starter seed 151. The jaws 152 maintain a heat transfer path withthe starter seed 151 as the molten metal solidifies. A mechanicalactuation structure 153 has a pair of moveable arms 155 that arenormally spring biased towards a closed position so that the surfaces154 are maintained in contact with the starter seed 151. The starterseed 151 is readily decoupled from the heat transfer apparatus 150 byapplying a mechanical force F to the ends of the arms 154 and 155.

Each of the pair of jaws 152 has an internal cooling passageway 530therein for receiving a quantity of heat transfer media 161 therethroughto change the temperature of the starter seed 151. While the heattransfer apparatus 150 utilizes an active cooling system the presentdisclosure also contemplates a passive cooling system. Preferably, theheat transfer media 161 is a coolant/sink for withdrawing energy/heatfrom the metallic starter seed 151. The heat is passed by conductionfrom the molten metal solidifying within the mold cavity to the starterseed. Thereafter the passage of cooling media through the jaws 152causes heat transfer through the starter seed to cause a thermalgradient and directional solidification of the molten metal within themold cavity. Further, many types of cooling media may be used. Thesimplest type being solids whose heat capacity and/or phase changes makethem attractive, such as but not limited to copper. A fluid, such aswater and/or argon may also define the cooling media. Further, heattransfer cooling media with higher heat transfer capacity or heattransfer include liquid metals like aluminum, tin, or mercury.

Referring to FIG. 39, there is illustrated an alternate embodiment 165of the heat transfer apparatus of the present invention. In a preferredform the thermal gradient across the seed is varied over time. Moreparticularly, in one embodiment the thermal gradient is low duringnucleation and substantially higher during growth of the crystal. Thethermal gradient in one form is greater than about 550.degree. F./inchat the liquid to solid interface. The heat transfer apparatus 165 issubstantially similar to heat transfer apparatus 150 with a distinctionbeing the capability to locally heat the metallic starter seed 151through the pair of jaws 166. Further, in one embodiment the starterseed can be locally heated and cooled at the same time. The ability toheat is utilized to adjust the heat flux at the seed and molten metalinterface. Since the heat transfer apparatus 150 and the heat transferapparatus 165 are substantially similar like features will be given thesame feature number. In a preferred embodiment of the heat transferapparatus 165, the jaws 166 are connected to a source of electricalpower by leads 531 and the passage of current through the jaws 166causes the resistant heating of the metallic starter seed 151. Theability to locally heat the metallic starter seed 151 is desirable tocontrol the crystal structure growth from the starter seed 151.

With reference to FIGS. 40 and 41, there is illustrated anotherembodiment 170 of a heat transfer apparatus for transferring heat with ametallic starter seed 171. In a preferred form the thermal gradientacross the seed is varied over time. More particularly, in oneembodiment the thermal gradient is low during nucleation andsubstantially higher gradient during growth of the crystal. The thermalgradient in one form is greater than about 550.degree. F./inch. Starterseed 171 is substantially similar to the metallic starter seed 151 andadditionally includes a pair of precision locating features 172. Themetallic starter seed 171 is located within an opening in the moldcontainer 80 and is placed in communication with the metal receivingcavity such that upon pouring molten metal therein a portion of themetallic starter seed 171 receives molten metal thereagainst and ispartially melted. The precision locating features 172 are designed andconstructed to receive a contacting end 174 of each of a pair of jaws173. A heat removal end 175 of each of the jaws 173 is positioned withina housing 180. The housing 180 has a passageway 176 therein for thepassage of a cooling media. The passage of the cooling media through thehousing 180 and across the heat removal ends 175 of the jaws is depicteddiagrammatically by arrows. In one embodiment, a local heater 178 iscoupled to the mechanical housing 180. Heater 178 is in a thermallyconductive heat transfer relationship with the pair of jaws 173 so as toimpart energy to the starter seed 171 through the contacting ends 174 ofthe jaws. The local heater 178 is controlled to adjust the heat flux atthe interface between the molten metal and the metallic starter seed. Amechanical actuator 177 is utilized to open the heat transfer apparatusjaws 173 from the position shown in FIG. 40 and then close the pair ofjaws 173 to the position shown in FIG. 41. The actuator 177 ispreferably a hydraulic actuator, however, other actuators having theproperties necessary to function in a casting environment arecontemplated herein.

With reference to FIG. 42, there is illustrated a mold 185 having aninternal cavity 186 for the receipt of molten metal. The mold 186 has avent end 187 for the passage of gaseous material to and from theinternal cavity 186 and starter seed receiving inlet 189 for receivingand snugly engaging a metallic starter seed 188. The metallic starterseed 188 is positioned to receive molten metal on a surface 188 a. Themetallic starter seed is not intended to be limited to the seed shapeshown in FIG. 42 as other seed shapes are contemplated herein. Locatedwithin the mold 185 is a starter seed auxiliary heater 195 and asupplemental mold heater 196. An insulator 190 is positioned between alower surface 185 a of the mold 185 and a heat transfer apparatus 191 tominimize heat transfer from the casting mold 185. In a preferred formthe thermal gradient across the seed is varied over time. Moreparticularly, in one embodiment the thermal gradient is low duringnucleation and substantially higher during growth of the crystal. Thethermal gradient in one form is greater than about 550.degree. F./inchat the liquid to solid interface.

The heat transfer apparatus 191 includes a pair of arms 193 and 194 thatare moveable into a position to abut and maintain contact with a surface198 of the starter seed 188. The abutting relationship of the heattransfer apparatus 191 and the starter seed 199 is maintainable untilthe arms 193 and 194 are positively released from the starter seed 188.A precision locating member 192 contacts a bottom surface 188 b of thestarter seed 188 so as to precisely locate the vertical height of themelt surfaces 188 a within the molten metal receiving cavity 186. Acooling media passageway 197 is formed in each of the pair of arms 193and 194 for the passage of cooling media therethrough. The molten metalwithin the cavity 185 transfers heat to the starter seed 188 which inturn transfers the heat through the surfaces 198 to the chilled pair ofarms 193 and 194. The cooling media flowing through the passageways 197removes the heat from the arms 193 and 194. Thus a temperature gradientis created through the starter seed 188 to cause directionalsolidification of the molten metal within the cavity 186.

With reference to FIG. 43, there is illustrated a mold container 200coupled with the heat transfer apparatus 191. The mold container 200 issubstantially similar to mold container 80 and substantially identicalfeatures will be indicated by like feature numbers. The thin wallintegral mold 45 has an internal cavity 186 with a top portion 186 a, abottom portion 186 b, and a side portion 186 c. Positioned proximate thetop portion 186 a is a vent 79 for allowing the passage of hot gaseousmaterial to and from the cavity 186. The starter seed receiving inlet189 is formed in the bottom portion 186 b, and the side portion 186 c isinsulated to minimize heat transfer from the side wall 49 of the mold.In a preferred form the thermal gradient across the seed is varied overtime. More particularly, in one embodiment the thermal gradient is lowduring nucleation and substantially higher during growth of the crystal.The thermal gradient in one form is greater than about 550.degree.F./inch at the liquid to solid interface. The shape of the molten metalreceiving cavity 186 is purely illustrative and is not intended to belimiting to the present invention.

Referring to FIG. 44, there is illustrated an alternate embodiment 201of a heat transfer apparatus for withdrawing heat through a starter seedpositioned within a casting mold. In a preferred form the thermalgradient across the seed is varied over time. More particularly, in oneembodiment the thermal gradient is low during nucleation andsubstantially higher during growth of the crystal. The thermal gradientin one form is greater than about 550.degree. F./inch. In oneembodiment, the integral heat transfer apparatus 201 has a starter seedportion 202, a precision locating surface 203, and a passageway 204therethrough. The starter seed portion 202 is received within and abutsa surface 550 of the thin ceramic shell of the mold. The verticalposition of the starter seed portion 202 is fixed by the precisionlocating member 192 which abuts the precision locating surface 203. Thepassageway 204 is formed through the heat transfer apparatus 201 and isdesigned for the passage of a heat transfer media. More particularly,the passageway is designed to be coupled with a pair of couplers 205(only one illustrated) that are firmly engagable and alignable with abearing surface 206 formed on the heat transfer apparatus. With the pairof couplers 205 connected with the heat transfer apparatus 201 andaligned with the passageway 204, a flow of heat transfer media can passthrough a passageway 551 within the coupler 205 and into the passageway204 of the heat transfer apparatus 201.

The bearing surface 206 and a corresponding surface on each of thecouplers 205 creates a substantially fluid tight seal to prevent theleakage of the cooling media around the joint. Further, in oneembodiment, the bearing surface 206 defines an electrical contact suchthat upon the pair of couplers 205 being mated with the heat transferapparatus 201 a circuit is completed and current can be passed throughthe heat transfer apparatus 201 to create a heater for heating the seedportion 202. The heat transfer apparatus 201 allows for the localizedheating of the starter seed portion 202 and the withdrawal of energyfrom the molten metal solidifying in the mold on the starter seedportion 202.

With reference to FIG. 45, there is illustrated a perspective view ofone embodiment of the energy transfer apparatus 201 removed from itsabutting relationship with the thin ceramic shell of the mold. In oneform, the energy transfer apparatus 201 has an integral main body 207,which includes the starter seed portion 202. The starter seed portion ispositionable within the seed receiving portion of a casting mold suchthat molten metal can flow across the melt surface 208 in the directionof arrow F. However, the present invention is not limited to an integralsystem and including an assembled system having a variety of geometry'sand flow paths.

With reference to FIGS. 46A and 46B, there is illustrated a portion of acasting mold 210. In a preferred form, the casting mold 210 is formed byselective laser activation or three dimensional printing, however, themold is not intended to be limited herein to a mold made by theseprocesses and can be produced by other processes known to one ofordinary skill in the art. The casting mold 210 includes a pour tube 211that provides a passageway for the delivery of molten metal to thecavity 212 within the integral casting mold 210. In one embodiment, astarter seed 213 is positioned within the casting mold 210 and islocated by a locating member 214 so as to place the initial meltingsurface 215 a of the starter seed 213 at a predetermined positionrelative to the discharge portion 216 of a diffuser 211 a. The diffuser211 a provides for the full coverage with molten metal of the initialmelting surface 215 a of the starter seed. The walls of the diffuserportion 211 a open at an angle .phi., which is preferably within therange of 15-45 degrees. The diffuser portion 211 a slowing the movementof the molten metal across the starter seed to increase the energytransferred to the starter seed 213 during an initial melt of a portionof the starter seed body. In one embodiment, the elevation of theinitial melting surface 215 and configuration of the diffuser portion211 a are selected to maximize the amount of heat removed from themolten metal and transferred to the starter seed 213 in order to melt aportion of the seed.

In one embodiment of the present invention a meltable member 220 ispositionable within the casting mold 210 such that the flow of moltenmetal melts the member 220 and delivers the material comprising themeltable member along with the molten metal into the mold cavity 212.The meltable member 220 is positioned within a portion of the pour tube211. However, the placement of the meltable member 220 may be in otherplaces such as the diffuser 211 a. In a preferred form, the member 220is a wire or mesh that does not substantially impede the flow of moltenmetal through the fill tube 211 and is readily melted by the heat of themolten metal. The meltable member 220 is melted and mixes with themolten alloy and imparts properties to the cast component such as, butnot limited to improved ductility and/or oxidation resistance. In oneform the meltable member 220 is formed of a reactive metal such as, butnot limited to a rare earth elements.

With references to FIGS. 47A-47C, there is illustrated the melt back ofa portion of a starter seed 188 as molten metal flows in the directionof arrow G across the melt surface 188 a. The starter seed 188 is ametallic member having a melt end and a base end that is contactablewith a heat transfer device to transfer heat to and/or from the member.A melt acceleration portion 225 is formed at the melt end and has aninitial height of material indicated by P. With reference to FIG. 47A,there is shown the melt portion in an unmelted state and it has a crosssectional area less than the cross sectional area of the base end. Aftera period of time in which the molten metal has flowed across surface 188a, the melt portion 225 has been partially melted back. Surface 188 b(FIG. 47B) indicates the profile of the melt portion 225 after havingmolten metal passed thereon for a period of time, and its height isindicated by Q. Moving to FIG. 47C, the process of melting continues asadditional molten metal flows across the melt portion 225 and theprofile is represented by 188C, and has a height indicated by R. As themelting of the melt portion 225 continues, the surface area of the meltportion from which heat transfer from the solidifying metal occursbegins to approach the same size as the surface area of the base 226 ofthe starter seed 188. When the melt back of the seed is completed in oneembodiment the melt portion has a cross sectional area substantiallyequal to the base end so as not to restrict heat transfer from themolten metal to the starter seed.

With reference to FIGS. 48 and 49, there are illustrated otherembodiments of starter seeds contemplated herein. Starter seed 230 has amelt acceleration portion 231 that is semi-circular in cross section,however, other geometric shapes such as but not limited to a groovedsurface and/or a knurled surface are contemplated herein. The starterseed 235 has a melt portion 235 a and a passageway 236 formed thereinfor the passage of a heat transfer media. It is understood herein thatthe starter seed can have other geometric shapes and may not have a meltacceleration portion 235 a, while still having a passageway for the flowof a heat transfer material. In an alternate embodiment there iscontemplated a plurality of internal passageways to form a moreintricate cooling passageway.

With reference to FIG. 50, there is illustrated another embodiment 230of the apparatus for dispensing molten metal from a casting apparatus,such as casting apparatus 115. The melting crucible 231 is substantiallyidentical to the melting crucible 122 except that the molten metal doesnot pass through an aperture in the bottom wall member. A molten metaldelivery passageway 232 has an input end 233 and a discharge end 234.Input end 233 is fed molten metal from beneath the surface of the moltenmetal and the passageway 232 is filled to the height of the column ofmolten metal within the crucible 231. The discharge of the molten metalfrom the delivery passageway 232 into the mold container 80 iscontrolled by the difference in pressure between the chamber 117 andchamber 118.

The molten metal delivery passageway 232 includes a positive moltenmetal flow control feature. In one embodiment the portion 232 a of thepassageway 232 functions as a flow control means. Upon the applicationof sufficient pressure to the molten metal within the crucible thepassageway 232 is filled with molten metal. Upon releasing the appliedpressure molten metal will return to the crucible and be maintained at aheight within the passageway substantially equal to the height of themolten metal within the crucible. In one form, the delivery of moltenmetal from portion 232 a and out nozzle 600 will have a predeterminedpressure and velocity controlled by the height “C” plus the pressuredifference between chamber 117 and chamber 118. The activation energynecessary to fill the passageway 232 is indicated by “D”.

In a preferred form of the apparatus the discharge of molten metal iscontrolled by the application of pressure to the molten metal within thecrucible 231. As discussed previously, the pressure applied to themolten metal can be created by advancing the metal stock 137 into themolten metal and/or by applying pressure to the surface of the moltenmetal with an inert gas. Upon the increase in pressure on the surface ofthe molten metal, additional molten metal is forced through the inputend 233 and up through the delivery passageway 232 to the output end234. At the output end 234 the molten metal passes through a nozzle 600to the mold container inlet. Upon release of the pressure on the moltenmetal, the molten metal beyond point 235 is delivered, and the remainingmolten metal within the passageway remains there and/or is returned tothe crucible 231. Therefore, the delivery of molten metal to the moldcontainer 80 is controlled by the difference in pressure between chamber117 and 118. In an alternate embodiment, the passage of molten metal tothe mold container 80 could be effectuated by lowering the pressurearound the container instead of raising the pressure on the moltenmetal.

With reference to FIG. 51, there is illustrated an alternate embodiment240 of the molten metal dispensing system for dispensing molten metalfrom a casting apparatus, such as casting apparatus 115. Moreparticularly, the molten metal dispensing system 240 is located withinthe upper chamber 117 and the mold 80 is located within the lowerchamber 118. Crucible 241 is substantially similar to the crucible 122and is heated by the heater 123 to melt the metal material stock. Acrucible discharge aperture 242 is formed in the crucible and alignedwith a passageway 243 through the wall member 114. A stopper rod 244 isdisposed within the upper chamber 117 and moveable between a positionwherein a sealing surface 245 engages the wall of the crucible aroundaperture 242 to prevent the passage of molten metal therethrough, andanother position wherein the sealing surface 245 is removed from theabutting relationship with the walls around the aperture 242.Gravitational forces will allow the passage of the molten metal into themold 80 upon the removal of the stopper rod sealing surface 245 fromit's sealing position.

With reference to FIG. 52, there is illustrated an enlarged view of thecrucible 122 with the molten metal dispensing system 125 locatedtherein. The crucible 122 having an aperture 700. The molten metaldispensing system 125 includes an outer passageway 250 and an innerpassageway 251 that are in fluid communication with each other and thecrucible 122. A plurality of filling apertures 252 allow the moltenmetal within the crucible 122 to flow into the outer passageway 250 ofthe system 125. Upon the outer passageway 250 being filled with moltenmetal, the molten metal can overflow into an inlet end 251 a of theinner passageway 251. The inner passageway 251 has an outlet end 251 bthrough which the molten metal flows to a nozzle 253. A portion 255 ofthe inner passageway 251 around the nozzle 253 allows the accumulationof molten metal which is used to maintain the temperature of the nozzle253 close to that of the crucible of molten metal.

In one embodiment, a heat shield and/or heater 254 is spaced from andpositioned around the nozzle 253 to mechanically guard the nozzle andreduce heat loss therefrom. The nozzle 253 passes through the aperture700 in the crucible and has a discharge aperture designed to provide aconcentrated stream of molten metal. In one form the stream of moltenmetal is discharged substantially vertical, however in alternateembodiments the stream is discharged in other relative directions. Inone embodiment the discharge aperture has a diameter of about 0.125inches, however, other sizes are contemplated herein. Further, thenozzle is self cleaning in that it purges itself every time thedischarge of molten metal is completed. More specifically, in oneembodiment the nozzle 253 has a pointed end 253 a.

The structure of the molten metal dispensing system 125 preferablyincludes an outer member 257 having the plurality of inlet fill holes252 formed therethrough with an inner member 256 spaced therefrom. Theinner member 256 and the outer member 257 are preferably formed ofalumina or other suitable ceramics, and the outer member includes fourequally spaced inlet fill holes 252, however other numbers and spacingof inlet holes is contemplated herein. The inner and outer members beingcoupled to the base of the crucible 122. More preferably, the dispensingsystem 125 defines a first upstanding outer tube 257 that is closed atone end and a second upstanding inner tube 256 spaced inwardlytherefrom. The inner tube 256 and outer tube 257 are coupled to thebottom wall member 701 of the crucible 122 and positioned around theaperture 700. In a preferred embodiment the inner tube 256 defines ametering cavity for holding a predetermined volume of molten metaltherein.

With reference to FIG. 52 a, there is illustrated an alternateembodiment of the molten metal dispensing system. The molten metaldispensing system 650 is positioned within a mechanical housing/crucible651. The mechanical housing has an interior volume 652 adapted toreceive molten metal therein. The molten metal dispensing systemincludes a member 653 having a passageway 654 formed therein. At one endof the passageway 654 is a molten metal inlet 655 and at the other endis a molten metal outlet. In an alternate embodiment only a portion ofthe molten metal dispensing system is located within the interior volumewhere molten metal is located. An inflection portion 655 is definedwithin the passageway 654. The molten metal enters the passageway 654and flows through the passageway to the height of the molten metalwithin the housing 651. Upon the application of a pressure to the moltenmetal within the mechanical housing the molten metal is driven to theinflection portion 655, and continues through the passageway 654 to themolten metal outlet and is discharged. In one form the molten metalflows in a first direction indicated by arrow A to the inflectionportion 655 and from the inflection portion 655 in a second direction asindicated by arrow B. The molten metal inlet 655 is located beneath thesurface 670 of the molten metal within the interior volume. In oneembodiment the molten metal dispensing system is integrally formed.

In a preferred form of the molten metal dispensing system 650 thepassageways have substantially upstanding portions that meet with theinflection portion to form a substantially U shape passageway. Further,it is preferred that the inflection portion is above the molten metalheight within the mechanical housing/crucible 651. In one form a portionof the passageway varies in cross-sectional area between the moltenmetal inlet and the molten metal outlet. In a more preferred form atleast a portion of the passageway tapers prior to the inflectionportion, and more preferably defines a passageway having afrustum-conical shape. In one embodiment the passageway 654 has a vent700 disposed in fluid communication therewith. However in an alternateembodiment the passageway does not have the vent 700 connectedtherewith. The vent has utilization for venting the passageway andallowing the purging of the passageway with a pressurized fluid. Thepresent invention contemplates other geometric shapes and sizes for thecomponents of the molten metal dispensing system.

With reference to FIGS. 53A-53E, there is illustrated the process ofdispensing molten metal from one embodiment of the molten metaldispensing system 125. As the unmelted metal material 137 is advancedinto the crucible 122 the material is melted and forms a quantity ofmolten metal 124. The molten metal 124 flows through the plurality offilling apertures 252 into the outer passageway 250 of the system 125.The continued advancement of the unmelted metal stock 137 into thecrucible and the subsequent melting thereof raises the height H of themolten metal within the crucible 122 to the height of the inlet end 251a of the inner passageway 251. In order to fill the innerpassageway/metering chamber 251 with molten metal it is necessary toapply an additional force to the molten metal 124 within the chamber.

The additional force can be applied by the continued advancement of theunmelted metal material 137 into the quantity of melted metal within thecrucible. A second method for increasing the pressure on the moltenmetal 124 within the crucible is to introduce a pressurized inert gasagainst the surface of the molten alloy. The additional pressure on themolten metal will cause the continued flow of molten metal through thefilling apertures 252. Subsequent overflowing of the molten metal fromthe outer passageway 250 to the inlet end 251 a of the inner passageway.The filling of the inner passageway is a relatively quick process as thefilling apertures 252 have been sized to allow an inflow of materialthat is significantly greater than the nozzle 253 can discharge from theinner passageway. Upon the inner passageway 251 being substantiallyfilled with molten metal, the pressure applied to the surface 124 a isremoved such that the inner passageway 251 no longer receives moltenmetal from the outer passageway 250 and the inner passageway dischargesits charge of molten metal through the nozzle 253 in a concentratedstream.

In one embodiment of the molten metal dispensing system, a sensor 800(FIG. 53D) is positioned proximate the nozzle 253 to detect the initialflow of molten metal from the nozzle. Upon the detection of the initialflow of molten metal from the nozzle 253, the sensor will send a signalto have the additional pressure removed from the surface 124 a of themolten metal. In one embodiment the signal is sent to a controller thatcontrols the application of pressure to the molten metal. The earlyindication of a slight molten metal discharge from the nozzle 253 issubstantially contemporaneous with the completion of filling of theinner passageway 251 due to the difference in the total size of thefilling apertures 252 and the nozzle aperture. In one embodiment, thematerial inflow through filing apertures 252 is significantly greaterthan the material outflow through the nozzle aperture.

With reference to FIG. 54, there is an illustration of the pressure ofthe molten metal as a function of time. In one embodiment illustrated inFIG. 36 the nozzle 253 is coupled in fluid communication to the inlet 78of the fill tube 52. Flow of molten metal can then be initiated byeither increasing the pressure in chamber 117 or reducing the pressurein chamber 118. The reduction in pressure in 118 can function to: vacuumthe internal mold cavity and thereby remove loose material like residualpowder; and/or reduce the mold gases level to protect reactive elementslike aluminum, titanium, and halfnium. Further, the increase in pressurein chamber 117 would aid in the fill of details in the mold cavity. Thehigher pressures within chamber 117 can be used to suppress reactionsamong many materials as well as reduce shrinkage from solidification.

With reference to FIG. 55, there is illustrated a gas turbine engineblade 30 positioned within furnace 801 for having post castingoperations performed thereon. The post casting processing operations fora single crystal and/or columnar grain casting include: a hot isostaticpressing operation; a homogenizing operation; and, a quench operation.The hot isostatic pressing operation involves placing the component 30within the furnace 801 and subjecting the component to high temperatureand pressure so as to remove porosity from the cast structure. In oneembodiment, the hot isostatic processing taking place at a temperatureof about 2375 to 2400 degrees Fahrenheit and at a pressure of about30,000 lbs. per square inch. The pressure is preferably supplied by aninert gas, such as argon. With reference to FIG. 55, the pressure isindicated by arrows 802 and the temperature is indicated by arrows 803.

Subsequent to the hot isostatic pressing operation, the component issubjected to a homogenizing operation that causes diffusion between theelements that may have separated during the solidification process andis designed to raise the incipient melting point of the cast structure.The homogenizing cycle is concluded by subjecting the component to aquenching step and subsequent tempering operations.

In one embodiment of the present invention, the three post castingoperations are combined into a sequential process within the furnace801. The hot isostatic pressing operation is performed within thefurnace 801 by raising the temperature and pressure within the furnace801 for a period of time so as to reduce the porosity in the casting.Thereafter, the temperature within the furnace 801 is raised to a valuewithin about 25 degrees Fahrenheit of the incipient melting point of thematerial forming the component 30. Preferably the temperature within thefurnace 801 is raised to within 5.degree. Fahrenheit of the meltingpoint of the material for a period of time. After the completion of thehomogenizing operation, the quenching operation is undertaken by thehigh pressure transfer of a cold inert gas into the furnace 801. Theaging of the cast component can continue under vacuum or pressure asdesired.

A preferred form of the casting operation allows the growth of a singlecrystal at a rate up to about 100 inches per hour and more preferably ata rate of about 60 inches per hour. However, other growth rates arecontemplated herein. The ability to grow the crystal at these ratesminimizes the segregation of elements in the alloy that occur duringslower solidification processes. Due to the decrease in segregation ofthe elements in the alloy, the homogenizing cycle of the post castingoperation can be accomplished in about 24 hours, and more preferably isaccomplished in about 2 hours. The utilization of a high thermalgradient and a relatively short starter seed lead to faster processing;lower shrinkage, which gives improved fatigue properties; and lowersegregation, which facilitates higher stress rupture strength.

With reference to FIG. 56, there is illustrated a metallic columnargrain starter seed 900. The starter seed 900 is designed to grow adirectionally solidified columnar grain component 901. The starter seed900 has very fine grains 902 that are desired to be replicated in thecast component. This strictly oriented crystallographic structure of themetallic starter seed 900 is used to impart this structure to the castcomponent.

While the invention has been illustrated and described in detail in thedrawings and foregoing description, the same is to be considered asillustrative and not restrictive in character, it being understood thatonly the preferred embodiment has been shown and described and that allchanges and modifications that come within the spirit of the inventionare desired to be protected.

1-158. (canceled)
 159. A method, comprising: building a integral ceramiccasting mold shell by a free form fabrication technique, the castingmold shell has an internal cavity adapted to receive a molten metal;reinforcing the ceramic casting mold shell; positioning a metallicstarter seed within the ceramic casting mold shell, the metallic starterseed is positioned to receive molten metal therein; filling the internalcavity with molten metal; and withdrawing heat through the metallicstarter seed to directionally solidify the molten metal within theinternal cavity.
 160. The method of claim 159, wherein said withdrawingincludes mechanically connecting at least one heat transfer member withthe starter seed to maintain a conductive heat transfer path with themetallic starter seed during the directional solidification.
 161. Themethod of claim 160, which further includes flowing a heat transfermedia through a passageway within the at least one heat transfer member.162. The method of claim 159, wherein the metallic starter seed includesa passageway formed therein, and wherein said withdrawing includesflowing a heat transfer media through the passage way.
 163. The methodof claim 159, which further includes selectively heating the metallicstarter seed.
 164. The method of claim 163, wherein the selectivelyheating includes passing a current through the metallic starter seed toresistant heat the seed.
 165. The method of claim 159, wherein saidbuilding includes three-dimensional printing of layers to form theceramic casting mold shell.
 166. The method of claim 165, which furtherincludes removing any unbonded material within the internal cavity priorto said filling.
 167. The method of claim 159, wherein said buildingincludes selective laser activation of layers to form the ceramiccasting mold.
 168. The method of claim 159, which further includescreating a build file to define the casting mold shell built in saidbuilding.
 169. The method of claim 159, which further includes providinga meltable member, the meltable member is positioned within the castingmold shell at a location wherein molten metal melts the meltable memberand mixes with the molten